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The Australian

Food Cold Chain

Logistic Guidelines 2013

FOR THE COLD CHAIN HANDLING, STORAGE AND

TRANSPORT OF REFRIGERATED FOODS: FRESH,

CHILLED, FROZEN (including ICE CREAM) FOR

SALE IN RETAIL AND FOOD SERVICE OUTLETS

An initiative of:

Australian Food and Grocery Council (AFGC)Australian National Retailers Association (ANRA)Refrigerated Warehouse and Transports Association of Australia

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Copyright Australian Food and Grocery Council (AFGC) 2013

Produced and adm inistered by the Austral ian Food and Grocery Counci l

All rights reserved

This document is subject to copyright. You may download, display, print and reproduce this content

for your personal use or for use within your business but only in an unaltered form and with the

copyright acknowledged. The document is not to be used for commercial gain through reselling,

rebadging or inclusion in a commercially available information or management program.

This document is intended as a guide only: legal requirements are contained in the Australia New

Zealand Food Standards Code and other applicable State and Territory Food or Health laws as

relevant to the jurisdiction within which goods are traded.

The information in this document should not be relied upon as legal advice or used as a substitute for

legal advice. You should exercise your own skill, care and judgement before relying on this

information in any important matter.

THIS DRAFT GUIDE IS SUBJECT CHANGE FOLLOWING THE REVIEW OF STAKEHOLDER SUBMISSIONS

AND CANNOT BE RELIED UPTON AS THE FINALISED GUIDE. INFORMATION ABOUT THE RELEASE OF

THE FINAL REVISED COLDCHAIN GUIDE WILL BE PROVIDED BY LATE MARCH 2013.

HOW TO MAKE SUBMISSIONS ON THIS GUIDE:

Submissions should be made in writing; using the Submission cover sheet - Cold Chain GuidelinesConsultation. While AFGC accepts submissions in hard copy to our offices, it is more convenient andquicker to receive submissions by emailing your submission directly to [email protected].

DEADLINE FOR SUBMISSIONS: 6pm (Canberra time) 8 March 2013There is no need to send a hard copy of your submission if you have submitted it electronically.

Extensions will only be granted due to extraordinary circumstances during the submission period.

Questions about making submissions or the application process can be sent [email protected]

Hard copy submissions may be sent to:

Australian Food and Grocery Council

Locked Bag 1, Kingston, ACT. 2604.

Australia

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TABLE OF CONTENTS

PREFACE 1

REVISION OF THE COLD CHAIN GUIDE (2013VERSION) 2

SECTION 1FOOD SAFETY REQUIREMENTS INTRODUCTION 4

FOOD SAFETY REGULATORY REQUIREMENTS 4

SECTION 2COLD CHAIN GUIDELINE REQUIREMENTS 6

2.1 COLD CHAIN 6

2.2 UNDERSTANDING TEMPERATURE AND TIME RELATIONSHIPS 6

SECTION 3NEVER WARMER THAN RULE 8

SECTION 4MAXIMUM OUT OF REFRIGERATION TIME LIMIT RULE 11

SECTION 5MIXED LOADS GUIDE 12

SECTION 6FIRST IN, FIRST OUT (FIFO) RULE 14

SECTION 7STORAGE-LOADING-DISTRIBUTION-RETAIL 15

FROZENGOODS-ICE CREAM 15

MANUFACTURING 16

FOOD PREPARATION AND REFRIGERATION 16

COLD STORAGE WAREHOUSING 18

RECEIVING PRODUCTS 18

COLD STORAGE 19

TEMPERATURE CONTROL REGIME FOR COLD STORES 19

TRANSPORT OPERATIONS 21

DISTRIBUTION VEHICLES 21REFRIGERATION PLANT (COMPRESSORS)OPERATIONS ON VEHICLES 22

DISPATCHING PRODUCT 23

ICE CREAM DELIVERY 24

MEETING DELIVERY REQUIREMENTS 24

UN-REFRIGERATED VEHICLES 25

RETAIL OUTLETS 26

RECEIVING DELIVERIES 26

ORDERING PRACTICES 26

MANAGING RETAIL COLD ROOMS 27

MANAGING REFRIGERATED FOOD RETAIL DISPLAY CABINETS 27

CORRECTIVE PROCEDURES 31

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FOOD SERVICE INDUSTRY 33

RECEIVING DELIVERIES 33

STORING AND RECEIVING STOCK 34

CONSUMER EDUCATION ON COLD CHAIN REQUIREMENTS 35

APPENDIX 1 37

MICROBIOLOGICAL INFORMATION RELATED TO THE COLD CHAIN 37

TEMPERATURE MEASUREMENT -DEVICE REQUIREMENTS UNDER FOOD STANDARDS CODE 39

TEMPERATURE MEASURING EQUIPMENT 41

CALIBRATION 42

VOLUNTARY ENERGY SAVING INDUSTRY AGREEMENT CALLED INFROMTHECOLD 43

FOOD ALLERGY RISKS AND VITAL 43

APPENDIX IITRANSPORT REGULATORY REQUIREMENTS 44

DANGEROUS GOODSROAD TRANSPORT 44

DANGEROUS GOODSMARITIME TRANSPORT 45

CHAIN OF RESPONSIBILITY REGULATIONS AND IMPACTS ON THE COLD CHAIN 46

CHAIN OF RESPONSIBILITY (COR)SUMMARY 47

APPENDIX III - GLOSSARY OF TERMS AND DEFINITIONS 49

ACKNOWLEDGMENTS 52

FURTHER ASSISTANCE 52

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PREFACE

There are more than 5 million food poisoning cases in Australia,1of which some may be

caused by food in which bacteria had grown to dangerous levels because the food was not

kept properly chilled for an extended period of time.

Australians are throwing away food worth $5.2 billion a year, of which more $1.1 billion worthof fruit and vegetables and $872.5 million worth of fresh meat and fish every year. 2Asignificant proportion of food waste is the result of bulk food purchases, and the food goingoff. One contributing factor for food waste is that food failings to achieve the useable bestbefore or use by date becauseof poor cold chain management.

Food Standards Australia New Zealand (FSANZ)Australia New Zealand Food Safety

Standard Code3(the Food Standards Code) specifies requirements to ensure the safety of

foods and that consumers are able to make informed choices. The Food Standards Code

specifies microbiological safety limits in foods, mandates the requirement that foods with a

shelf-life of less than 2 year must display either a best before or use by date, and specifies

the minimum requirements for food businesses in the hygienic handling and storage of foods

that minimise the risk of contamination or deterioration of foods.

What is the Cold Chain?

Over the last two decades, foods now travel greater distances from the paddock to plate.

The average food anecdotally is moved in and out of refrigeration control at up to 14 times

across the Cold Chain before consumption. In one SA study, broccoli took 39 steps along

the cold chain - having as many as 23 operators and 21 stages involved on the way - toreach its consumer4.

The cold chain consists of the series of businesses engaged in manufacturing, transporting,

storing, retailing and serving refrigerated and the flow of chilled and frozen foods (i.e. frozen

or chilled) foods through them to consumers, who buy those products and transfer them

home for food preparation. The effectiveness of the cold chain in maintaining the safety,

durability and quality of foods relies on controlling product temperature through each and

every step in the cold chain. The delivery and receipt of safe and high-quality food products

to consumers requires the food premises at all links in the cold chain to understand and

meet cold chain temperature requirements for chilled and frozen foods.

Food businesses receiving foods are legally required to ensure that foods being delivered

are in good condition - not contaminated and packaging not damaged. The Standard

(Section 3.2.2) states that potentially hazardous food must be transported under temperature

control (if chilled at +5C or below or if hot at +60C or above, or if frozen, not partly thawed),

and must not have been left outside of temperature control for longer than safe time limits.

Product temperatures warmer than those in the Food Safety Standard will the support the

rapid growth of bacteria and microorganisms, and the longer that products are kept at

1Abelson P. The cost of foodborne illness in Australia. Australian Government Department of Health and Ageing, 2006

2http://www.ces.org.au/Other%20stuff/Australia_Institute_What_a_waste_of_food.pdf

3www.foodstandards.gov.au

4www.foodprocessing.com.au,Oct 6, 2005

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elevated temperatures, the greater the potential for food-borne illness and the more rapid the

deterioration in product quality.

Revision of the Cold Chain Guide (2013 version)

The Australian Food Cold Chain Logistics Guideline 2013 is the result of the formal industry

review of the The Australian Cold Chain Guidelines 1999and provides best practice

recommendations for transport, logistic and safety requirements to ensure the safety and

quality of chilled and frozen foods. This document is advisory only and is additional

guidance to regulatory requirements of Australian food law.

This 2013 Cold Chain Guide review has made amendments so as to:

a) provide a consistent interpretation of requirements of the Food Standards Code;

b) outline procedures intended to meet the safety requirements of the Food Standard

Codes requirementsas well as consistent product quality; and

c) offer clearly designed guides to assist the Food Industry supply chain on transport

and logistics requirements that include a focus on food quality guides plusincorporate all the vehicle and driver procedures needed to adopt as a minimum

covering logistics and safety measures.

Food businesses must comply with Food Standards Code requirements and other relevant

legislation in the supply of safe, quality food. In Australia, this legislation includes the

Consumer and Competition Act 2010,theImported Food Control Act 1992and State and

Territory Food Acts, and State Fair Trading Acts.

Transportation of goods also need to comply with Chain of Responsibility legislation in each

State, including when Dangerous Goods are combined on loads as per the AustralianDangerous Goods(version 7), as well as State Work, Health and Safety legislation and or

Codes of Practice adopted by the Australian Retailers under theRetail Logistics Supply

Chain Code of Practice.

This guide is intended to strengthen the Australian cold chain for food. It have been

designed to ensure the development, implementation and ongoing maintenance of systems

that meet essential cold chain requirements and ensure the safety and quality of chilled and

frozen foods. The guideline will assist businesses to avoid negative impacts on food product

quality and safety, reducing the risk of food spoilage and avoiding rejection of shipments by

receiving businesses, thereby reducing unnecessary food waste by industry and consumers.

Benefits to the Consumer and the Industry

Todays consumer is looking for safe, durable, quality foods at affordable prices5. The last

two decades have witnessed a profound change in the eating habits and retail food

purchasing patterns of Australian consumers6. Convenience foods of every type are well

established and continue to enjoy popularity. In particular, refrigerated foods comprise one

of the fastest growing segments of the Australian grocery and foodservice industries.

Maintaining consumer confidence in refrigerated foods, as the basis for continuing sales and

profit growth, depends on an efficient and effective system where product safety and qualityare protected at each link of the cold chain.

5www.who.int/foodsafety/publications/capacity/en/Englsih_Guidelines_Food_control.pdf

6www.pc.gov.au/__data/assets/pdf_file/0019/113761/retail-industry.pdf

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The Cold Chain guidelines recommend practices for the handling of refrigerated foods in

each link of the cold chain, with the aim of ensuring that products reach the consumer at

optimum safety and quality. They do not cover in detail all manufacturing practices that

occur prior to the manufactured product being placed into cold storage, nor final handling by

the customer.

Whilst every effort has been made to provide a complete guide for cold chain businesses to

develop and implement effective food safety programs that may or may not include food

quality aspects, the importance of appropriate training using appropriately written standard

operating procedures for all staff involved in the cold chain process cannot be overstated.

Training and Education

Those involved in the cold chain should:

liaise with customers and suppliers to explain the need for the cold chain and itspurpose;

agree to setting minimum shelf-life limits when foods are being transported from one

food premise to another food premise;

organise an ongoing program of training for personnel covering housekeeping,

hygienic discipline and process control requirements, management training in safety

and quality, and retraining and refresher training to reinforce knowledge; and

review policies and operating procedures recommended by the cold chain and

suggest appropriate modifications.

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SECTION 1 Food Safety Requirements Introduction

Food Safety Regulatory Requirements

The Australia New Zealand food standards system is a cooperative arrangement between

Australia, New Zealand and the Australian State and territories to develop and implementuniform food standards. The system is governed by food legislation in State, Territory, New

Zealand and the Commonwealth of Australia, including theFood Standards Australia New

Zealand Act 1991(the FSANZ Act).

The FSANZ Act establishes the mechanisms for the development of joint food regulatory

measures and creates Food Standards Australia New Zealand (FSANZ) as the agency

responsible for the development and maintenance of the Food Standards Code.

Food Safety considerations must be assessed and managed, from raw materials to

processed manufactured foods and throughout the supply chain. Food safety issues include:

Microbiological risk

Bacteria, fungi, viruses, parasites and the toxins produced by those microorganisms.

From cross-contamination during the cold-chain, from leaking meat products or from

nearby quarantined damaged goods leading to unexpected microbial contamination

Chemical risk

In raw materials, including herbicides, pesticides, antibiotics, veterinary chemicals,

and heavy metals, as well as naturally occurring toxins in the food itself

From cross-contamination during the cold chain whilst being transported or stored,

including cleaning and pest control chemicals leakage, processing aids, food

additives and allergenic ingredients

Physical hazards

Within the food or its source, including bone chips, hair, leaves, seeds, manure.

Foreign objects such as glass, metal, plastic, personal effects and packaging

components.

From cross-contamination during the cold-chain, from nearby quarantined damaged

goods leading to unexpected physical contamination

Chapter 3 of the Food Standards Code specifies food safety requirements that apply to food

businesses in Australia only, and do not apply in New Zealand. They are:

Standard 3.1.1 Interpretation and Application

Standard 3.2.1 Food Safety Programs,

Standard 3.2.2 Food Safety Practices and General Requirements

Standard 3.2.3 Food Premises and Equipment

Standard 3.3.1 Food Safety Programs for Food Service to Vulnerable Persons

Food Safety Programs:State or Territory Authorities may require specific classes of food

business to introduce this requirement for food safety control.

As described inStandard 3.2.1under Purpose.

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The Food Standard 3.2.1 is based upon the the principle that food safety is best

ensured through the identification and control of hazards in the production,

manufacturing and handling of food as described in the Hazard Analysis and Critical

Control Point (HACCP) system, adopted by the joint WHO/FAO Codex Alimentarius

Commission, rather than relying on end product standards alone. This standardenables States and Territories to require food businesses to implement a food safety

program based upon the HACCP concepts. The food safety program is to be

implemented and reviewed by the food business, and is subject to periodic audit by a

suitably qualified food safety auditor.

While it is mandatory for some food businesses to comply with Standard 3.2.1 and

implement a food safety program, other food businesses not required to implement a food

safety program may choose to do so for their own business purposes.

Those food businesses that use HACCP system need to demonstrate this preventative

approach has been implemented correctly by demonstrating compliance with Standard 3.2.2through documentation, record keeping and review.

All Australian businesses that handle food intended for sale, or sell food, in Australia are

required to comply with State and Territory Food (or Health) Acts. This legislation generally

does not apply to 'primary food production' activities. Consequently, businesses, such as

farms, that engage in primary food production are not required to comply with the Food

Safety Standards unless they engage in any process involving the substantial transformation

of food or the sale or service of food directly to the public. Additionally, in most jurisdictions,

the Food Safety Standards do not apply to businesses regulated by any other food

production legislation, for example State and Territory Meat or Dairy Acts.

Food safety regulations issued nationally through Food Standards Australia/New Zealand

(FSANZ) now also apply to most parts of the food transport chain. In Australia, when the

legislation was fully introduced in 2002, it also classified food transporters as food handling

businesses and they must be registered and comply with the various state-based food acts.

The above Food Safety Standards do not all apply to food businesses in New Zealand.

However, New Zealand food businesses are required to operate under theNew Zealand

Food Hygiene Regulations 1974or adopt a Food Safety Programme (FSP), under the

provisions of theNew Zealand Food Act 1981.Certain primary production industries

handling meat production also require to implement a FSP.

By following the Australian Cold Chain Guidelines, operators of food businesses in the cold

chain can establish Cold Chain complimentary systems that help to meet these legal

requirements.

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SECTION 2 Cold Chain Guideline Requirements

2.1 Cold Chain

The cold chain consists of the series of businesses engaged in manufacturing, transporting,

storing, retailing and serving refrigerated and the flow of chilled and frozen foods (i.e. frozenor chilled) foods through them to consumers, who buy those products and transfer them

home for food preparation. The effectiveness of the cold chain in maintaining the safety,

durability and quality of foods relies on controlling product temperature through each and

every step in the cold chain.

Each food business therefore depends on the commitment of each and every other link in

the cold chain to deliver safe, quality products to the consumer. Based on the risks in

multiple transfers some key guidelines have been developed in the past and within this

document called the

NEVER WARMER THAN RULE (see Section 3) , and the

MAXIMUM OUT OF REFRIGERATION TIME LIMIT GUIDE(See Section 4)

2.2 Understanding Temperature and Time Relationships

Refrigeration storage of foods at low temperature is an excellent method of extending the life

and useability of foods.

Refrigeration slows the growth of microbes and slows the natural deterioration and spoilage

of fresh foods, keeping foods safer and edible for longer than would otherwise be the case.

Refrigeration does not kill microbes, and some potential food poisoning bacteria are able to

grow under normal refrigeration temperatures, so there are limits on how long foods can besafely held under refrigeration.

Rate of Deterioration

The safety and quality of refrigerated foods depends very much on the time and temperature

history of the product. Every person involved in the handling of frozen or chilled foods

throughout the cold chain has an impact on this history.

Exposing refrigerated foods to warmer-than-the-recommended cold chain temperatures can

lead to the rapid growth in microorganisms, resulting in decreased shelf-life through spoilage

and potentially unsafe food. In addition, product quality issues such as loss of shape andpoor texture can occur. Poor cold chain management will have a negative impact on product

quality, especially delicate, perishable produce like fresh horticultural products. Examples of

Softening, bruising, unwanted ripening, bacterial growth and texture degradation can all lead

to spoilage or even rejection of the consignment.

Standards and regulations for a particular industry may conflict with the recommendations in

this guideline. Examples of this may include the Standing Committee on Agriculture and

Resource management (SCARM Reports) with specific regulations in the meat industry and

some requirements of the Australian Quarantine Inspection Service (AQIS) and Export

Approved Arrangements

7

.

7http://www.daff.gov.au/aqis/export

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Before any business decides that a food can be stored or transported at a temperature

above +5C, a thorough validation step must be completed. This will often include a

microbiological assessment of safety, a physical test examination quality, and an

assessment of the impact on shelf life of the product. The elevated temperature being set (if

validated as safe) should be written into any contract covering storage or transport and in

Food Safety Programs.

Breaking the Cold Chain

A break in the cold chain at the critical control points identifiedwhether caused by failure to

follow established procedures or faulty equipmentcan result in food which is likely to

cause food poisoning and/or irreversible damage to the quality of the food product.

The critical points for food safety and food quality can be found through a process of hazard

identification. HACCP analysis of chilled foods typically places an emphasis on the control

of microbiological spoilage and the risks posed to vulnerable populations through inadequate

temperature control. For example, inadequate temperature control could result in the grow

of Listeria monocytogenesin dairy products and processed meats that could present a

serious health risk.

A break in the cold chain for chilled foods can reduce shelf life through an increased growth

of spoilage organisms such as moulds or psychrophilic bacteria such as Pseudomonads,

which have a pungent odour creating doubt about the products integrity at consumer levels

and increase wastage losses across the supply chain downstream from the break.

The microbiological tables in Appendix 1 illustrate how microbial growth varies according to

storage temperature and the significant difference that only 1C can make to the growth

rates of microorganisms. There are also details on the minimum temperatures at which food

pathogens are known to grow.

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SECTION 3 NEVER WARMER THANRULE

These Cold Chain Guidelines refer to the NEVER WARMER THAN rule, which is designed

to ensure that safety and quality is maintained throughout the cold chain handling process.

The recommended product temperature rules that constitute the Cold Chain NEVERWARMER THANrule are as follows:

All CHILLED foods must be stored and handled at temperatures between 0C and

+4C and ensure the product temperature is NEVER WARMER THAN+5C to

maximize product safety and quality unless otherwise specified.

FROZEN food products (including Ice Creams) must be stored or handled NEVER

WARMER THAN-18C.

Due to problems of heat exchange with other products in a cold store or transported on thesame vehicle, some businesses may require products normally stored at room temperature

to be transported and delivered at +4C to ensure the NEVER WARMER THAN+5C rule

does not impact on the chilled food products in a mixed load. See also Section 5.

A supplier and cold chain customer must establish in a specification or contract, prior to

supply of the product, the conditions, especially of temperature and time that must be in

place at all times to ensure the safety and quality of any product when notadhering to the

NEVER WARMER THANrule.

It is a prerequisite of HACCP and other food safety plans that records of control points be

kept for audit and review. For the Cold Chain these records should include temperature of

stock taken upon receipt, the temperature of storage areas and display cabinets, and the

internal temperature of refrigerated transport vehicle. (i.e. throughout the food supply chain).

Manufacturers, owners or authorized representatives must be notified immediately of a

breach of the NEVER WARMER THANrule so as to establish a course of action for the

assessment and possible withdrawal and disposal of damaged of unsafe stock. The above

temperature requirements and the means of measurement should be written into all Food

Safety Plans and any transport contract arrangements.

The NEVER WARMER THANtemperatures are based on a combination of science that has

been validated and an extensive history of safe, quality food delivery at these temperatures.

The NEVER WARMER THANtemperature of -18C for frozen food is based on the

traditional Imperial temperature of 0F, at which enzymatic activity effectively ceases. As

frozen food is warmed above -18C, the natural enzymes present become increasingly

active, which can result in the development of unacceptable off-flavours and, ultimately, the

complete deterioration of the food, even though it may still appear frozen.

Ice cream is a complex colloidal system and includes ice crystals in a concentrated unfrozen

aqueous phase. These products should be treated as the product most tested on receipt and

dispatching (i.e. the canary effect).

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Always ensure effective storage and handling practices are being used to maximize product

safety, maintain product quality and avoid physical damage from forklifts, pests, chemical

leaks, poor hygienic cleaning and or poor housekeeping.

A microbial tables in Appendix 1 illustrate how microbial growth varies according to storage

temperature and the significant difference that only 1C can make to the growth rates ofmicroorganisms. There are also details on the minimum temperatures at which key food

pathogens are known to grow.

Summary of the NEVER WARMER THANrule:

In general, all products must be kept at temperatures NEVER WARMER THANtherecommended temperature.

Always keep chilled foods at a temperature between 0C and +4C to ensure

the product temperature is NEVER WARMER THAN+5C.

Always keep frozen foods and ice cream NEVER WARMER THAN-18C.

This rule also requires that product dispatched from a manufacturing or processingcentre arrives at the next site NEVER WARMER THANthe above temperatures.

Variations allowed to the NEVER WARMER THAN rule

The temperature of +5C may not be applicable for all chilled foods; as some may require

higher or lower temperatures. Section 2.3 of these guidelines has further information on

chilled products that may in individual cases require conditions above or below +5C. It

must also be remembered that product safety and quality can be affected by holding it with

another product that is at a different temperature. This must always be considered before a

decision is made to vary from the NEVER WARMER THANrule.

Colder Storage items:

Some foods that require refrigeration for safety and quality reasons may require storage or

transportation at temperatures colder than +5C.

Examples include:

some varieties of fish and shellfish and products using these items as ingredients;

modified atmosphere packaged meat products; and

value added fresh produce (e.g. alfalfa sprouts, washed and packed salads).

Warmer Storage items:

Other refrigerated foods MAY NOT require storage or transportation at temperatures as cold

as +5C for quality or safety reasons.

Examples of these might include.

Fermented or cured meats, such as some prosciutto hams and salami-style products,

which, by nature of the ingredients and processing conditions may be safe to store

even at ambient temperatures, but which may be kept cold for eating quality;

Processed and mature cheeses;

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Specific thaw-baked pastry products;

Margarine; and

Certain bulk citrus and tropical fruits such as bananas and mangoes, which suffer

quality problems through the chilling injuries incurred at the cold refrigeration

temperatures that are lower than their reference distribution temperatures.

Consumer Education

The businesses in the cold chain cannot directly control the final link: the consumer.

The clear labelling of products in declaring clearly within the Storage and Cooking

Instructions area of labels with the appropriate handling and storage instructions is, also an

important element in providing consumers with essential information relating to storage

temperatures and maintaining the safety and quality of the product after purchase.

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SECTION 4 MAXIMUM OUT OF REFRIGERATION TIME LIMITRULE

As a general rule, all products that leave refrigeration zones within the cold chain handling

processes should never pass the following MAXIMUM OUT-OF-REFRIGERATION-TIME

LIMIT RULE:

Out Of Time Limit Rule

Frozen and Chilled foods that are received in uncontrolled temperature docks or temperature

controlled ante-rooms are now being given clearly endorsed industry standards called

maximum out-of-correct-temperature-time limit rule designed to maintain product safety

and optimize product quality control that will lead to a reduction in shrinkage plus consumer

complaints.

The recommended tolerances to be established for Ice Creams and other frozen foods at

receipt docks or when being put on display at retail levels should ALSO meet

the newly proposed MAXIMUM OUT-OF-REFRIGERATION-TIME LIMIT RULE

shown below; as well as

meeting the Food Standards Australia New Zealands Mandatory Microbiological

Limits in Standard 1.6.1 and

meeting the Food Standards Australia New Zealands commodity Advisory

Microbiological Limits within User Guide Standard 1.6.1

For Chilled goods

Where chilled stock is being un-loaded or dispatched in ambient (normal

temperature) conditions, the maximum time chilled stockis permitted out of the

correct refrigeration storage requirement is 20 minutes (See Note 1 below) Where chilled stock is being un-loaded or dispatched in +15Cair conditioned ante-

room (temperature zone)conditions, the maximum timechilled stock should

meet the 20 minutes guide due to risks of bacterial growth for such foods (See Note

2 below)

For Frozen Goods

Where frozen stock is being un-loaded or dispatched in ambient (normal

temperature) conditions, the maximum time frozen stockis permitted out of the

correct refrigeration storage requirement is 20 minutes (See Note 1 below)

Where frozen stock is being un-loaded or dispatched in +15Cair conditioned ante-

room (conditioned temperature zone)conditions, the maximum timefrozen stock

is permitted out of the correct frozen storage requirement is 60 minutes;

Where frozen stock is being un-loaded or dispatched in +5C refrigerated ante-

room (chilled temperature zone)conditions, the maximum timefrozen stock is

permitted out of the correct frozen storage requirement is 90 minutes

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SECTION 5 MIXED LOADSGUIDE

Take appropriate measures to ensure effective product temperature separation (where

possible). For example, use partitions, locate frozen products adjacent to evaporators and,

where possible, use dual temperature vehicles and separate compartments.

Issues may also arise when raw products (for example, uncooked meats) are transported

with fully processed ready-to-eat products. Stacking raw product that readily leak (e.g.

cartons of fresh meats or poultry) on top of ready-to-eat product or fresh foods that may

never be cooked can easily lead to cross-contamination and serious illness.

Always try to avoid carrying mixed loads of products that demand two or more un-

segregated loads with different temperature regimes, so as to minimize temperature loss

issues relating to food safety and food quality. Typically occurs in rural and remote

distribution areas, including barges and other difficult to transport delivery situations.

Where such mixed loads are unavoidable, it is imperative that the temperature integrity of all

refrigerated products is protected. The temperature should be maintained to meet the

requirements of the product demanding the coldest conditions. Three recommendations

follow for these situations:

A. vehicles used to carry mixed fresh, chilled, ambient and the coldest being frozen

goods (including ice cream products) should have compressors set to no warmer

than -22oC to allow for temperature increase from ambient and or chilled goods

in the same compartment that in effect would not affect the ice cream and other

heat sensitive frozen products being carried.

B. vehicles used to carry mixed ambient, fresh, and chilled goods be set to no

warmer than +2oC and no cooler than -1oC to prevent temperature increase from

ambient goods within the same compartment that would compromise the

temperature of high risk chilled products.

C. it is recommended that mixed loads be validated using data-loggers or validation

checks to confirm and set maximum distance that loads should be carried on the

fleet being used due to difference in temperature zones, equipment types, un-

segregated food typesfresh, chilled, frozen, ambient or dry goods.

Additionally, recognizing that different frozen and chilled products may be stored,transported and displayed together, the NEVER WARMER THANrule requires that the

temperatures of different food products do not affect the temperatures of accompanying

products. While some fresh foods (e.g. unwashed potatoes, bulk citrus fruits) can be stored

warmer than +4C, they are required to comply with the NEVER WARMER THANrule when

moving with other chilled foods through the cold chain.

To assist the food industry and transport operators meet the NEVER WARMER THAN rule

and the MAXIMUM OUT OF REFRIGERATION TIME LIMIT rule, the following table

provides a guide to vehicle thermostat settings when transporting mixed loads.

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Table 1: Thermostat setting guide for mixed loads.

Frozen food

-18oC or less

Chilled food

0oC to +4

oC

Fresh food

+5oto +7

oC

Confectionery

approx +15oC

Ambient goods

+15oC to 30

oC

Thermostat

setting

X X +15oC (all runs)

X X X +5oC (all runs)

X X X X+2

oC (run > 2 hr)

+4oC (metro run)

X X +4oC (all runs)

X X-18oC (metro run)

-22oC (run > 2hr)

X X -22oC (all runs)

X= food is present on load with Thermostat setting as guideline setting to validate or use.

Metro run= run that has frequent delivery stops nearby distribution centre within 2 hrs.

NOTE 1: The temperature thermostat settings can and may need to vary based on the

volumes being carried of different food types. The above is a guide only and may not be

suitable under specific circumstances.

NOTE 2:Other options may be applied but must be validated to ensure the settings protect

frozen stock and protect fresh stock. Options may include thermal protective devices using

shrink-wrapping, pallet covers, or other segregation options.

Care should be taken when transporting fresh items on mixed load to ensure cross-

contamination of the ready-to-eat or fresh product by the leaking raw product does not occur.

Transporting raw and ready-to-eat foods and fresh foods in separate compartments in the

vehicle is one possible solution to this issue.

Fresh foods delivered in mixed loads risk being damaged quickly by the delivery thermostatsetting of the vehicle:

very cold temperature settings on vehicles can freezer burn or affect respiration of

fresh foods damaging the outer product (e.g. browning of bananas)

very warm temperatures settings on vehicles can increase respiration rates of fresh

fruits and vegetables leading to faster enzymatic and other deterioration leading to

loss of product at retail and consumer levels (e.g. wilting lettuce from hot delivery

means high leaf wastage pre-sale or post-sale)

The potential dangers of transporting raw and ready-to-eat and fresh products must beconsidered when a transport business is developing its food safety plan and when

contracting is being established for services.

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Non-food items are also sometimes transported with refrigerated foods especially on food

service and route trade vehicles. Care should always be taken to ensure that non-food

items such as chemicals, pesticide products, and high microbial-based products like potting

mix do not contaminate the refrigerated foods. Stacking non-foods above refrigerated foods

without extra levels of protection can easily lead to contamination of the refrigerated foods.

Garbage and waste should never be transported with refrigerated foods.

Under certain circumstances, damaged unsafe or poor-quality product being returned from

customer premises may be in the same vehicle as acceptable, safe high-quality product

provided they are clearly marked and isolated onto different pallets or zones. Such

circumstances typically include when delivery vehicles are requested to return damaged or

out-of-date stock to its origin, or when stock damaged in transit is returned to the cold store

or depot. Under these limited circumstances, all care should be taken to ensure cross-

contamination does not occur.

Products not fit for their original purpose must be recorded upon collection on approved

returns documentation and be clearly identified or clearly isolated during transport so that

safe, high-quality product is never mixed with unsafe, poor-quality product. Goods upon

return then must be receipted back at the cold store facility into approved quarantine storage

areas for assessment and re-sorting and not mixed with safe quality goods until assessed as

safe.

SECTION 6 FIRST IN, FIRST OUT (FIFO) RULE

Rotating Stock

To assist in correct stock rotation is based on the first-in isfirst-out(FIFO) rule, ensuring

that stock which has been in the system longest is moved first by:

ensuring that shipping cartons are marked with a recognizable product identification

showing pack size and batch or date code.

recording and monitoring date marking or batch codes on product.

applying an appropriate receival date code to the product if date code details on the

individual shipping cartons are not be visible.

ensure that there is sufficient residual shelf-life available at the time of receipt of

stock, taking into account the anticipated holding period in storage, to ensure the

product will still be in date when put out for retail sale.

To ensure stock and inventory are correctly rotated with date codes consider recording these

in an inventory information management system as appropriate.

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SECTION 7 STORAGE-LOADING-DISTRIBUTION-RETAIL

FROZEN GOODS - Ice Cream

Ice cream and ice cream products are particularly heat sensitive and at risk of quality defectsdue to fluctuating or elevated storage temperatures above -18C and should preferably be

stored between -22C and -30C.

Ice cream is an emulsion of fat, milk solids not fat (MSNF), sugar, emulsifier and stabiliser.

The aqueous phase contains a concentrated lactose solution along with other sweeteners

salts. When aerated and quickly frozen, tiny ice crystals are responsible for the smooth

product texture, while the MSNF concentration gives the characteristic creamy taste8. The

texture quality of ice cream is extremely sensitive to temperature change and any damage is

irreversible.

At no time in the cold chain, from the manufacturing facility through cold store, distribution

and retail display to purchase from the retail outlet, should ice cream or ice cream products

be allowed to become warmer than -18C. The maximum out-of-refrigeration-time limits in

this guideline have been established and validated primarily for the successful control and

sale of these sensitive products.

Ice cream should be handled and stored in strict accordance with the recommended Cold

Chain guidelines and temperatures along with the manufacturers specifications.

As is the case with all other refrigerated products, it is the responsibility of each individual

operation to determine and maintain the environmental temperature requirements and

handling practices necessary with these systems to ensure products are NEVER WARMER

THANthe specific temperatures.

In view of the specific needs and sensitivity of ice cream products, a separate section has

been included in most chapters of this document.

Heat Shock of Ice Cream

The texture quality of ice cream is irreversibly damaged if the temperature is allowed to cycle

into a range above -18C and colder temperatures.

With improved technology in ice cream manufacturing, smaller sized fat globules are now

produced being into ice cream products. These are very heat sensitive and will easily break

down from any raised temperature fluctuations in the cold chain. The separation of fat and

moisture out of the homogenous emulsion condition into fat and ice layers is a direct cause

by this temperature break down from any thawing. As a consequence, the product becomes

icy, granular and hard. This is known as heat shock and frequently results in shrinkage and

consumer complaints of under filling.

Some manufacturers of ice cream recommend storage of their products at temperatures

colder than -18C to further avoid heat shock damage to their product.

8www.dairyscience.info/ice-cream-/154-ice-cream-mix.html

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TIME versus Product Temperature graphical illustration of the difference in deterioration for

ice cream compared to other frozen foods.

The crucial time pointoccurs at 20 minutes and

differentiates between

quality impact and safety

impact. Ice cream has a

faster deterioration rate

than other frozen foods

such as frozen chicken or

frozen vegetables.

The following SEM images show the progressive increase in crystals size in ice cream with

increasing temperature.

Manufacturing

The cold chain starts with the growers and manufacturers. The first stage consists of the

harvesting, selection, receipt, and preparation, handling and processing of raw materials.

These Cold Chain guidelines begin with recommendations for the packing and refrigeration

of finished food products at manufacturing level (not growing level), as there are many

different ways for cold chain controls at harvest level that differs from product to product.

Food Preparation and Refrigeration

Chilled Foods

Chilled foods should not be transported at temperatures warmer than +5C (note exceptions

in section 2.3) and be delivered with enough shelf life.

Chilled foods with a short shelf life should be transported without delay and be delivered with

enough shelf life deemed acceptable by the next Cold Chain recipient. Potentially

hazardous foods include processes fresh fruit and vegetable products, chicken meat, red

meat and dairy products, which can support the rapid growth of food poisoning bacteria.

Quality impact

zone ice cream

-180

C

Temperature

Time20 minutes

-20

C

Safety impact

zone frozen food

Ice Cre

am

Other Frozen

Food

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Frozen Foods

Ensure an even temperature is obtained throughout the product. In most cases, frozen food

has a shelf life of two years and should not be transported until sufficient time has elapsed to

achieve a core temperature of -18C.

Guard against exposing frozen foods and ice cream to temperatures warmer than -18C

after it leaves the freezer and ensure out-of-refrigeration-time limits are being met.

Verification: Treat the Cold Chain Guidelines as a random check point (RCP) not as critical

control point which requires frequent monitoring to confirm staff training; inventory system

controls and storage operation procedures to effectively implement the guidelines.

Packaging the Product

Select consumer packs designed to:

minimize the risk of microbial, chemical and physical contamination.

maintain product safety and quality through effective insulation.

minimize product dehydration and give optimum durability and shelf life.

provide storage and product information that is legible to consumers.

food-grade compliant testing against either EU, USA or Australian FSC Standards

Sourcing and using shipping cartons with:

dimensions that minimize the air space within the carton.

sufficient structural strength for the demands of storage, handling, and transport.

adequate support for the temperature and humidity conditions anticipated through the

Cold Chain handling steps.

Clearly Identifying the Product

In the Food Standards Code in Chapter 1: General Food Standards are the requirements in

Part 1.2 on all the Food Labelling and other Information Requirements. The Standards 1.2.1

to 1.2.11 provide the relevant guidelines on how to mark and label product clearly.

Marking the product with a recognizable pack size and batch or date code at the

manufacturing stage permits traceability, effective stock rotation and the efficient operation

of the cold chain.

GS1 is the global organization operating controls that lead to GS1 Automatic Identification.

GS1 provide the industry standards for the uniform numbering and barcoding of foods, and

are available fromGS1 Australia.

In general, always:

display a legible code on two adjacent sides or two opposite sides of the packaging;

display the word frozen or chilled (or a specific holding temperature) and the

product name in a prominent place on consumer packs; and

include simple instructions clearly indicating the temperature below which the productmust be stored.

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Cold Storage Warehousing

The second stage of the cold chain includes the receipt, storage and dispatch of refrigerated

foods into cold storage warehouses.

The Role of the Cold Storage Operator

Effective cold store management helps to ensure the safety and quality of the product, as

well as proper stock rotation. As many of the necessary operations as possible should be

performed under temperature-controlled conditions and if not possible should meet the OUT-

OF-REFRIGERATION-TIME Limits set out within this Cold Chain Guideline 2012 document.

Receiving Products

Always:

identify the product immediately upon arrival at the cold store is as ordered.

check condition of vehicle before unloading to ensure product has been storedhygienically.

check that co-mingling of hazardous goods has not cross-contaminated the foods

such as pesticides, chemicals, and high bacteria loaded products e.g. potting mix.

record on the designated Inwards Goods Check Sheets, the receipt date / time and

conduct at least two product temperatures of each consignment received.

check and record that Use-By, Best-Before, or Packed on Date, or batch codes, are

in place to meet the regulatory requirements and also meet the minimum shelf-life

limits agreed between both parties.

mark and/or transfer completed product, after performing above receipt checks, are

moved as quickly as possible to storage areas and ensure that at least the MaximumOut-Of-Refrigeration-Time limits set within this guide are met.

Note: Records should be retained for compliance with food safety plan requirements, and

will be an important part of traceability and investigation of product failure. Typically two

years retention is recommended.

As a general guideline, all products that leave refrigeration in the cold chain during the cold

chain delivery-receipt transfer process should never pass the MAXIMUM OUT OF

REFRIGERATION TIME LIMIT RULE. In certain cases where the delivery environment is

severe such as some food service delivery route runs, use of trolleys to customers need to

be carried out as fast as possible.

The optimum way to protect goods is to deliver from cold areas on vehicles into cold holding

areas at customers but the above NEVER WARMER THAN rule and MAXIMUM OUT OF

REFRIGERATION TIME LIMIT rule help to set clear guidelines for staff to follow and meet.

If a consignment is received outside the appropriate temperature range, corrective measure

should be pre-determined within the Food Safety Program and action taken only after

consultation with the owner of the goods. These corrective actions should be defined and

agreed upon by both parties in advance to ensure the safety and quality of the product.

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Cold Storage

St ock Ro ta tion

The cold storage operator should consult the owners of the goods to ensure correct rotation

procedures are followed as and when minimum receipt limits are not being met as agreed.

Air Circu la tio n

Cold Storage Operators should always allow adequate air circulation around packed product

on floor stacks, in anterooms and or on racking to ensure the even distribution of cold air and

control of product temperature from refrigeration compressors.

Products stored on pallets direct onto floor spaces in anterooms, docks, and cool-rooms or

on racking should be designed to be kept a minimum distance of 15 centimetres from wallsand floors and 60 centimetres from ceilings. These distances may be varied according to

specific needs, provided effective child-air circulation is achieved and maintained.

Never store product in direct physical contact with walls, floors or ceilings.

Where racked product storage exists and is located underneath ceiling located refrigeration

compressors, adequate protection measures should be in place from defrost systems

splash, hot water and icing to protect stock from water damage.

Temperature Control Regime for Cold Stores

Controlling Temperatures

Achieving and controlling the appropriate temperature is essential when storing refrigerated

foods. See Sections 3 and 4 for clear information on the NEVER WARMER THAN rule and

the MAXIMUM OUT-OF-REFRIGERATION-TIME LIMIT GUIDE.

Accurate thermometers should be used to help maintain the proper environment in the cold

store or warehouse. Wherever practicable, use continuous-recorder digital or analogue

thermometers. All thermometers should be calibrated regularly (at least annually).

See Appendix 1 Temperature Devices for more information.

To control cold store temperatures effectively:

minimize air temperature variation to avoid microbial safety, reduction in quality and

reduction in useable shelf life of product.

minimize door openings and/or traffic movement in and out of the cold store.

take prompt steps to reduce the product temperature should any increase occur.

ensure defrost cycle systems are adequately designed to prevent any product

heating up, and if excessive triggers alarms ensure prompt corrective action.

conduct regular checks to maintain compressor, defrost cycle, thermostat and

cooling tower equipment are running in good working order and are safe. ensure damaged walls and door seals that could leak cold air out and allow hot

ambient air in are promptly repaired.

ensure optimum stacking patterns and floor layout to facilitate airflow.

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Recording Temperatures in Storage Rooms

Ensure:

each storage room is monitored by a thermometer (preferable a recording

thermometer with an alarm sensor linked) that is positioned to indicate the warmest

return air temperature in the room;

monitoring is sufficiently frequent to detect trends in the malfunction of temperature

control;

alarms are provided to indicate unacceptable temperature variation or equipment

malfunction;

alarms are regularly checked to ensure they are operational; and

charts are retained from recording thermometers for an agreed period (at least 2

years for frozen goods shelf life is recommended) or a period set by the businesss

auditing authority.

Warehouses may engage in providing checks and or passing this information onto owners or

those interested in the condition of the stock (i.e., contracted warehouse scenarios or

manufacturers).

Corrective Procedures

If at any stage while at the cold store the product becomes warmer than NEVER WARMER

THAN RULE, immediately contact the owner, agent or authorized representative of the

goods to confirm what corrective actions as pre-determined should be activated and or

establish a course of action for temperature recovery and/or to assess the acceptability andsafety of the affected product.

The owner of the goods will then advise the cold storage operator as to what action to take,

which may involve placing the product on hold, rejecting the product or releasing the product

for further movement through the cold chain. The course of action will vary according to the

product concerned and the degree of temperature abuse.

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Transport Operations

The third stage of the cold chain involves the transport of a refrigerated product to its

destination.

The Role of the Transport Operator

Transport refrigeration vehicles are NOT DESIGNED to chill product down to a temperature

but are only designed to MAINTAIN the existing product temperature. Care must be taken

when loading pre-chilled or frozen product loaded into a vehicle which is transporting a

mixed loads. See Section 5.

Road transportation for the Cold Chain is carried out in vehicles which have insulated walls,

specially designed flow chutes, corrugated floors and are fitted with evaporation units which

create the cold air necessary to maintain the temperature required for the product. Off-road

transportation can be either rail or shipping using special containers with evaporation units.

All carriers must have appropriate operating procedures for the proper management of

refrigerated foods during transit. Refrigeration units must be serviceable and capable of

maintaining the required product temperature at all times.

Calibration checks on such refrigeration compressor units on vehicles and the frequency of

refrigeration performance checks using temperature data-loggers, radio frequency

monitoring systems and or thermometer checks on goods are key items to be included in a

Transport Vehicle Operators developed Food Safety Program.

Distribution Vehicles

Distribution vehicles are used for the final delivery to the Retail and or Food Service point of

sale location. Such vehicles are often used on multi-delivery work and product may be

subject to temperature variation.

This may be caused by a number of factors other than heat transfer through the body of the

vehicle, including ambient air temperature, compressors defrost cycle timings, load mix, run

duration, and the number of door openings.

Transport vehicles are not normally designed to lower product temperatures but to maintain

the existing products temperature when stored in the correct transport temperature zone;

therefore all previous handling and processing steps in the cold chain must be controlled to

ensure correct temperature is being maintained.

Distribution vehicles should be designed and operated with adequate refrigeration capacity

to ensure the product temperature is maintained. It is recommended that these refrigeration

units be designed and maintained to exceed the refrigeration areas load space

requirements by at least 10%. Partitions should be provided to help minimize the effect of

product drops and mixed loads.

Loads should be organized to avoid intermingling of fresh, frozen and chilled food products

on same pallets during distribution runs. Exceptions can be determined if based on

validation checks. These exemptions are based on checks when it is proven that faster drop

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point handling prevents significant temperature loss or out-of-refrigeration-time limits being

breached on a specific run by intermingling the load, or where no bulkhead exists.

Each delivery vehicle must have a means by which temperature can be monitored and

recorded. Typically, chart-recording systems, data-logging monitoring systems and GPS Wi-

Fi monitoring systems are being used.

If the recorded receipt temperature after testing using calibrated thermometer devices (see

section 9 of these guidelines) is outside that specific for the product, then corrective action

must be taken, including contacting the owner of the goods.

At all times, avoid exposing product to ambient temperatures and other adverse conditions.

Plastic strips and secondary doors should be provided to reduce heat-gain during door

openings. The integrity of door seals and the effectiveness of insulation during transport

also are factors in reducing heat-gain.

Air Circu la tio n

The construction of distribution vehicles and the stacking of cargo should allow optimum air

circulation throughout the vehicles at all times to ensure the product arrives at temperatures

within the specified range.

Maintenance of Compressor systems must encompass the following system physical and

calibration checks on areas including:

Microprocessor / Thermostat

Engines

Electrical

Refrigeration

Structural Integrity

These will vary from vehicle type compressor type and also vary on what insulation and

bulkhead, strips, curtains system is in place so these maintenance and calibration checks

should be adopted based on equipment manufacturer specifications.

Refrigeration Plant (Compressors) Operations on Vehicles

Refrigeration plants (Compressors) on vehicles should be frequently maintained and

operated to ensure food safety and quality at all times.

During loading:

ensure truck is pre-chilled to remove excess heat from insulated walls at times and

temperature checks are set as to meet never warmer than requirements.

turn off the vehicles refrigeration plant when the doors are open (these can be

automated using door sensors or engine ignition devices).

close the doors and turn on the refrigeration plant when loading and unloading is

completed (these can be automated using door sensors or engine ignition devices). establish efficient defrost cycles using thermostat devices or manually defrost the

refrigeration unit 15 to 20 minutes after loading where practicable or maybe after

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each delivery (if duration between drops is lengthy) to prevent ice build-up and air

temperature loss causing product temperature changes.

arrange maintenance corrective actions (as soon as possible) if the equipment is not

operating in accordance with specifications.

Dispatching Product

The temperature of product dispatched from cold stores should be maintained in accordance

with the NEVER WARMER THANrule and the MAXIMUM OUT-OF-REFRIGERATION-

TIME LIMIT GUIDE. See Section 3 and 4 for these guidelines.

All products that leave refrigeration in the cold chain dispatch process from a cold storage

warehouse during the cold chain transfer processes should never pass MAXIMUM OUT-OF-

REFRIGERATION-TIME LIMITS.

Transport refrigeration vehicles are NOT DESIGNED to chill product down to a temperature

but are only designed to MAINTAIN the existing product temperature. Thus, vehicles mustnot be used or expected to deliver product to a customer at lower temperature as when

loaded. They should expect that during drops, external higher temperature will impact on the

product temperature resulting in increased temperatures.

Always

complete product load-out movements as quickly as possible so that the temperature

of the product remains NEVER WARMER THANits recommended storage

temperature

avoid delays in cross-docking operations that meets the Maximum OUT-OF-

REFRIGERATION-TIME LIMIT RULE record the dispatch date and temperature of each consignment. Temperature

checks should be performed on two to three pallets across the entire load, for

example the front, middle and or rear pallets of the load. Retain records as required.

Provide all logistics documentation necessary to transport operators showing:

an accurate description of the loaded cargo;

the temperature of the goods released for transport;

the total weight of the goods to allow for effective legal distribution of the goods on

the vehicle;

an acceptable lead-time to arrange a safe trip plan for its drivers to follow; the number of drops that may affect the delivery cold chain performance;

a check that vehicle load restraints have been confirmed as adequate; and

the set temperature the customer requires for successful delivery.

During transport:

carry out periodic temperature verification checks during transport or confirm when

receipted at each drop.

If the product temperature is higher than the owners specification, take corrective

action to maintain product safety and quality.

Corrective action may include returning the stock to its origin for assessment orreducing the temperature of the vehicle to lower the temperature of the product.

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Care needs to be taken when attempting to reduce a products temperature due to

the limitations of vehicles, so that safety and quality are not compromised. Contact

the shipper immediately and agree on the required course of action.

Ice Cream Delivery

Refrigerated vehicles used for the cartage of ice cream are to be operated in maintain a

product temperature of -18C or colder. Distribution vehicles carrying mixed temperature

product, including ice cream for multi-pallet delivery, must be equipped with refrigeration

plants with adequate capacities and airflow to ensure the product arrives at temperatures

within the stipulated range.

Where such mixed loads are unavoidable, it is imperative that the temperature integrity of all

refrigerated products is protected. The temperature should be maintained to meet the

requirements of the product demanding the coldest conditions.

It is recommended that distribution vehicles used to carry mixed fresh, chilled, ambient and

the coldest being frozen goods (including ice cream products) in the same compartment:

should have compressors set to no warmer than -22oC to allow for temperature

increase from ambient and or chilled goods that in effect would not affect the ice

cream and other heat sensitive frozen products being carried; and

should validate alternative setting of thermostats for differing runs and seasonality (if

setting a different standard)

Route trade and distribution vehicles (generally smaller, servicing more deliveries per day),used to carry ice cream should use plastic strip curtains, secondary doors or some other

mechanism to reduce heat-gain during loading and unloading.

Meeting Delivery requirements

If not loading vehicles using +5C ante-rooms, then refrigerated vehicles should have

compressors turned on and be pre-chilled down to a wall temperature of approximately

+5C to ensure the load space walls temperatures are not overly hot (i.e. retain the ambient

heat from hot days) that will have an impact on refrigerated foods being loaded below +5C.

Before leaving a pick-up point, the transport operator should have received notificationshowing:

an accurate description of the loaded cargo;

the temperature of the goods released for transport;

the total weight of the goods to allow for effective legal distribution of the goods on

the vehicle;

an acceptable lead-time to arrange a safe trip plan for its drivers to follow;

the number of drops that may affect the delivery cold chain performance;

a check that vehicle load restraints have been confirmed as adequate; and

the set temperature the customer requires for successful delivery.

The temperature of the goods to be transported should be able to be maintained after

allowing for multiple drops and each temperature check is recorded on the trip log sheet.

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Transport operators must ensure that refrigerated product leaves the cold store and is

transported NEVER WARMER THAN and the MAXIMUM OUT-OF-REFRIGERATION-TIME

LIMIT GUIDE. See Section 3 and 4 for these guidelines. This is an even more crucial issue

for long-distance transport, where goods may be in the vehicle for a longer period of time.

All transport vehicles and containers should be able to have access to accuratethermometers (preferably recording thermometers), which are calibrated regularly as per

Australian Food Standards requirements. Provision of an easy-to-read indicating

thermometer is also recommended.

Temperature measuring using indicative non-destructive testing by surface temperature

devices and core temperature testing methods are discussed in Appendix 1Temperature

measurement.

Other non-destructive testing may include additional cold chain monitoring devices such as:

RFID passive tags to monitor temperature fluctuations. Heat Sensitive film onto cartons or packaging that may highlight any temperature

abuse (i.e. if gets out of specification)

Un- Refrigerated Vehicles

Vehicles not fitted with cooling units or inadequately insulated vehicles i.e. unrefrigerated or

substandard insulation capacity are under these Cold Chain Guidelines 2012 are not

recommended to distribute fresh, chilled or frozen foods.

If any business uses an unrefrigerated vehicle for the transport of refrigerated products, for

example, for quick runs between sites, then it must be established that this does notcompromise the safety or quality of the product. Remember the product must meet both the

NEVER WARMER THAN rule and the OUT-OF-REFRIGERATION-TIME LIMIT rule.

The foods permitted to travel out of refrigeration easily would be dry foods such as bread,

cereals, biscuits, nuts, seeds, shelf stable canned, bottled foods, UHT packed goods plus

fats and oil products such as margarine, butter and other non-dairy fats and oils that typically

can be transported outside these limits.

Verification checks:

The temperature of the chilled or frozen foods to be transported un-refrigerated should be

checked using suitable devices e.g. Data loggers, so drivers are aware of vehicle and route

run performance after allowing for multiple customer drops.

Testing checks should determine optimal drops for the types of products being transported

and also after considering variables such as delivery mechanisms being used e.g. trolleys,

vehicle conditions and the seasonal changes that occur externally.

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Retail Outlets

The fourth stage of the cold chain is the management of refrigerated foods on the premises

of the retail outlet.

The Role of the Retailer

Retailers must ensure that refrigerated product for sale is kept in conditions that meets Food

Standards Code requirements and will maintain product safety and quality. The product

must arrive from the manufacturing or processing centre or cold store or wholesaler, and be

stored, at temperatures NEVER WARMER THAN:

+4C for chilled foods to ensure that the product temperature is NEVER WARMER

THAN+5C (note exceptions in section 2.3); and

-18C for frozen foods and ice cream.

Receiving Deliveries

As transport vehicles are being prepared for unloading, storage areas and laneways to

correct storage areas should be confirmed before opening doors so that goods never reach

the MAXIMUM OUT-OF-REFRIGERATION-TIME Limits set in this Cold Chain Guideline.

All vehicles should be recorded onto Inwards Goods Summary check sheets with vehicle

cleanliness, non-food physical contamination risk checks and temperature checks.

Always move refrigerated foods into the retail display cabinet or buffer stock cold room

immediately after unloading from the transport vehicle within these Maximum Out-of-

Refrigeration-Time Limits.

Those rules are:

maximum of 20 minutes if no refrigeration control exist at receipt docks or

maximum of 60 minutes for frozen foods (if areas room temperature control is set to

no warmer than +15oC) or

maximum of 90 minutes for frozen foods (if areas room temperature control is set to

no warmer than +5oC).

Records should be kept of the temperature of refrigerated products when they are received.

Ordering Practices

Retail-refrigerated display cabinets may not be as effective as dedicated cold stores in the

maintenance of product temperature due to frequent movements of ambient into the units

and more frequent defrost cycles.

Operators should base their food ordering on a number of factors to account for the potential

impact on product safety and quality such as:

Cool-room storage areas capacity for stock holding

ability to maintain effective stock rotation practices using clearly observable date

code, packed on date or colour coding systems

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available racking to keep FIFO (First In-First Out) protocols

quick stock turnover trends are noted and checked on sale of product sold in retail

display cabinets before ordering

stock lead times from suppliers or cold store warehouses;

length of maximum shelf-life and or minimum agreed receipt shelf-life pre agreed with

supplier/ cold store operater

frequency of possible temperature fluctuations associated with exposure to

numerous defrost cycles during the time the product may remain in the display

cabinet

See also section 3.5, Rotating Stock

Managing Retail Cold Rooms

Controlling Cold Room Temperatures

All retail cold store management must ensure that the product temperature is maintained in

accordance with the NEVER WARMER THANrule.

Refrigerated Cold rooms should, ideally, be equipped with temperature-recording devices

linked to suitable alarm devices. As a minimum standard, indicating easy-to-read digital or

analogue displayed thermometers should be installed. All types of temperature measuring

devices should be calibrated regularly as per Section 9.

Always meet the NEVER WARMER THAN rule

maintain product temperature at 0C to +4C to ensure that the product temperature

is NEVER WARMER THAN+5C for chilled foods;

maintain product temperature NEVER WARMER THAN-18C for ice cream and

frozen foods;

Always

use a cold store large enough for proper stock rotation and control.

ensure that products are stacked off the floor and away from walls and ceilings to

ensure good air circulation.

defrost the cold store as often as necessary to maintain refrigeration efficiency.

keep cold store doors closed to avoid loss of cold air and prevent excessive ice

formation, and use a plastic strip curtain or other method to prevent cold air loss.

record the temperature at which the product is held.

Managing Refrigerated Food Retail Display Cabinets

The Product Load Line

All refrigerated food display units (typically called coffins and or display cases) must be

marked with a maximum holding product load line. This applies whether the food display

unit is horizontal (bin or chest type) or vertical in design. All products in excess of the load

line limitation should be returned to the cold room in the original outer container. Loading

product beyond the load line will seriously affect product temperature, impact on efficiency of

defrost cycle systems and quickly prejudice product safety and quality.

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Loading Consumer Packs

Consumer packs are very sensitive to temperature change once removed from the shipping

carton before placing into the appropriate temperature controlled refrigerated display unit.

To avoid loss of safety and quality, products must be kept under refrigerated conditions at alltimes and should not be left unattended when loading retail cabinets or marking prices. It is

good practice to recommend and keep to an absolute minimum the time chilled and frozen

products can spend out of refrigeration while being stacked or loaded into the cabinet in the

retail area.

After unloading from the carton, product should be loaded into retail cabinets as soon as

possible to maintain core product temperature and should not reach the Maximum Out-of-

Refrigeration-Time Limits.

Key Guidelines for stocking cabinets

1. Put Frozen foods and Ice Creams into Retail cabinets immediately to prevent severe

quality loss.

2. Put chilled high risk potentially hazardous foods (e.g. pre-mixed salads, sprouts,

dips) away immediately to ensure the loading does not breach the NEVER WARMER

THAN rule

3. The suggested MAXIMUM OUT OF REFRIGERATION TIME LIMIT rule of 20

minutes normally applies or until NEVER WARMER THAN rule is reached.

Further processing

If chilled foods are subjected to further processing at the retail level (for example, slicing

decanting portioning or repacking), they should be handled at +4C or colder to ensure that

the product temperature is NEVER WARMER THAN+5C during the further processing

stage.

This process must be determined as part of an individual businesss food safety program

which typically recognizes HACCP principles for the products and the processes. If

necessary because of temperature change and after the process is complete, re-cool the

product to +4C as quickly as possible preferable in a cool room, prior to placing in the

display counter.

Controlling Temperatures

Retail cabinets are not designed to lower product temperatures, therefore all handling and

processing steps earlier in the cold chain must be controlled to ensure correct temperature is

maintained.

Never display foods required under the Food Standards Code to be stored and sold

refrigerated to be put on sale outside the appropriate refrigerated cabinets.

Each refrigerated food retail display cabinet must have a means by which the temperaturecan be monitored and recorded. Thermometers built into the cabinet should indicate the air

temperature around the product as a way of indicating product temperature. Where

practicable, night covers should be employed to conserve energy and product temperature.

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Hot product chilling

Where hot or heated foods, either as individual products or plated meals, is being cooled for

the purpose of storage, transport and may be reheated for meal service, or may be ready-to-

eat as a cooked-chilled food.

Firstly, if the product is a potentially hazardous food able to support the rapid growth of

microbes, the hot product chilling process must be validated and confirmed that using the

existing cold rooms can effectively meet the Food Standards Code processing requirements,

that is, when cooling cooked potentially hazardous food, cool the food:

(a) within two hoursfrom +60C to +21C; and

(b) within a further four hoursfrom +21C to +5C;

Secondly, the same cooling of hot products inside existing cold rooms must not have any

impact on other cold room products stored nearby within the cold rooms, as the transfer of

heat to other product may pose a significant risk as heat is transferred onto such productleading to bacterial growth and or quality losses.

Finally, risks of leaking during the chilling process should be accounted for with the use of

suitably designed metal trays with protective coverings that can capture juices, prevent

cross-contamination, easily transfer temperature from the air flow system underneath the

product (as opposed to plastics), and can easily be cleaned and sanitized.

Note: Refer toAIFST Cook-Chill Guidelines (blue book)for more detailed information.

All retail cold store management must determine and ensure that the product temperature ismaintained in accordance with the NEVER WARMER THANrule and the Food Standards

Code requirements.

Always:

transfer product to the cabinet or cold room quickly to avoid increases in

temperature; and

meet the Out-Of-Refrigeration-Time Limits set in this Cold Chain Guide; and

ensure accuracy of the thermometers by regular calibration.

Never: load products into a retail display cabinet if product temperature is warmer than:

+4C for chilled foods to ensure that the product temper